# US 8,784,089 B2 · Foamed tools

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 8,784,089 B2
- Document ID: US8784089B2
- Status: Granted
- Kind: B2
- Application number: 12/514,102
- Filed: 2007-11-09
- Published: 2010-04-22
- Granted: 2014-07-22
- Earliest claimed: 2006-11-09
- Assignees: Umeco Structural Materials (Derby) Limited
- Applicants: Thomas Joseph Corden; Mark Raymond Steele
- Inventors: Thomas Joseph Corden; Mark Raymond Steele
- Web page: https://patentgrep.com/patent/US8784089B2

## CPC

- B29C 70/44: using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
- B29C 33/38: characterised by the material or the manufacturing process (B29C33/44 takes precedence)
- B29C 33/3814: {Porous moulds (adapted for vacuum forming B29C51/365)}
- B29C 33/56: Coatings {, e.g. enameled or galvanised}; Releasing, lubricating or separating agents {(in-mould coating B29C37/0028; using or applying separating agents B29C37/0067)}
- B29C 33/565: {Consisting of shell-like structures supported by backing material}
- B29C 70/549: {Details of caul plates, e.g. materials or shape}
- B29K 2707/04: Carbon
- B29K 2821/00: Use of unspecified rubbers as mould material
- B29K 2909/08: Glass
- Y10T 428/249969: Of silicon-containing material [e.g., glass, etc.]
- Y10T 428/249991: Synthetic resin or natural rubbers
- Y10T 428/249993: Hydrocarbon polymer
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A tool for use in forming moulded articles, the tool comprising a tool body formed of a foamed material, a resinous material on the tool body and elastomeric material between said tool body and resinous material to inhibit the movement of resin from the resinous material into the tool body. The invention also provides a method of manufacturing a tool, a method of moulding articles using such a tool, and elastomeric material for use in forming a tool. One particular application of the tools of the present invention is in the formation or manufacture of moulded articles using curable, resinous composite materials.

## Claims

### Claim 1

A moulding tool, the tool comprising a tool body formed of foamed material, a resinous material on the tool body and elastomeric material located between said tool body and resinous material to inhibit the movement of resin from the resinous material into the tool body and to provide a compliant layer or interface between the tool body and the resinous material, wherein the elastomeric material comprises a fluoroelastomer.

### Claim 2 (depends on 1)

A tool as claimed in claim 1, characterized in that the elastomeric material is located directly between the tool body and resinous material and is in the form of a layer.

### Claim 3 (depends on 1)

A tool as claimed in claim 1, characterized in that the elastomeric layer is continuous.

### Claim 4 (depends on 1)

A tool as claimed in claim 1, characterized in that the elastomeric layer further comprises one or more of a low temperature cure silicon elastomer, butyl elastomer and/or polyurethane elastomer.

### Claim 5 (depends on 1)

A tool as claimed in claim 1, characterized in that the tool body comprises one or more of a foamed carbon material, foamed thermoplastic, foamed glass and foamed ceramic.

### Claim 6 (depends on 1)

A tool as claimed in claim 1, characterized in that the resinous material comprises carbon fibre reinforced resinous material.

### Claim 7 (depends on 1)

A tool as claimed in claim 1, characterized in that the resinous material comprises a blend of resins, some of which are cured at relatively low temperatures, and some of which are cured at relatively high temperatures (over 200° C.).

### Claim 8 (depends on 1)

A tool as claimed in claim 1, characterized in that the resinous material provides the surface(s) of the tool on which articles and structures can be formed.

### Claim 9

A method manufacturing a molding tool, the method comprising forming a tool body of foamed material, applying an elastomeric material to be between the tool body and a resinous material of the tool such that the elastomeric material acts to inhibit the absorption of resin from the resinous material into the tool body and to provide a compliant layer or interface between the tool body and the resinous material, wherein the elastomeric material comprises a fluoroelastomer.

### Claim 10 (depends on 9)

A method as claimed in claim 9, characterized in that the elastomeric material is applied in a curable condition and is cured in situ on the tool body.

### Claim 11 (depends on 9)

A method as claimed in claim 9, characterized in that the resinous material is applied directly to the elastomeric material such that the elastomeric material is in the form of a layer located directly between the tool body and the resinous layer and acts to inhibit the movement of resin from the resinous layer into the interstices of the tool body.

### Claim 12 (depends on 9)

A method as claimed in claim 9, characterized in that the resinous material is applied in a curable condition.

### Claim 13 (depends on 12)

A method as claimed in claim 12, characterized in that the elastomeric and resinous materials are cured during a single cure process.

### Claim 14 (depends on 12)

A method as claimed in claim 12, characterized in that the elastomeric material inhibits movement of resin from the resinous material when the resinous material is in a curable condition and during cure of the resinous material.

### Claim 15 (depends on 12)

A method as claimed in claim 12, characterized in that the tool body is formed or shaped to be of approximate geometry of the desired tool prior to application of the elastomeric and resinous materials.

### Claim 16 (depends on 1)

A method of moulding an article comprising laying a material to be moulded on to the resinous material of the moulding tool as described in claim 1, and subjecting the material to be moulded to conditions to facilitate moulding.